I am going to leave the sprockets alone, the 530 chain will fit on the 520 sprocket that is on the motor(its just a little wider) and will run fine.
I have run similar chain/sprocket setups before and had no issues with a wider chain than the sprocket was made for.

thanks for the kudos, I try to do my best, it does not always work out perfect the first time, but where is the fun in having everything work all the time?

as for the turbine, not sure I can help you there, but if you wanted to turbocharge it, I do have experience installing them on motors never designed for them.

Impressive. I have a garage, a welder, and lotsa tools and it still would have taken me months to finish something like that...

That said, I think you will probably want to weld the rear engine mount sooner rather than later, and also make some bushings where the swing arm bolt goes through even if it's just a whole ton of washers stacked on the bolt. Can't wait for the ride report!

Did you ever tear the old engine down to see if the cdi/coil was the cause of it melting?

Truckin,
I greatly admire your ingenuity and skills so please take the following as constructive "advice."

As a tool maker,engineer and fabricator with many projects under my belt I'd like to offer some suggestions.

The BW frame uses the engine as a stressed member. Since there is no lower engine cradle,the engine itself has to provide the strength to hold the frame together and stabilize it.
Your engine will be strong enough but the mounts you have made will not.

The front mounts may be good enough but would be considerably stronger if you weld the plates to the frame.
The back mounts need some more work.
If you land this from a jump,the frame will try to "open the horseshoe" that is the engine cradle.The front mount will try to pull the back of the engine away from the swing arm pivot.
The lower mount using the u bolts will do little to prevent this. They will break or deform as the angle iron is already doing from the bolts being tightened.
The upper mount is two "L" shaped pieces of iron bolted together. If you make spacers to fill the gaps between the brackets and swing arm you will have good side to side strength but virtually no strength when the motor tries to move away from the swing arm bolt.Simply welding the two pieces of angle together will not give you the strength you need. The forces will try to straighten them out. You need the top plate to hold the bracket in the shape it is now.

Laying a shaped plate on the top and bottom of these two "L" brackets,that covers them from one side of the engine mount to the other side and extends backward out over the swing arm bolt,and then welding all together will greatly strengthen this area.Do top and bottom if you can.

My concerns are this,if you ride this very hard at all, this frame will be a "flexible flyer" and quickly break.The results could hurt you.

Please go back and look at the conversion I did with the two stroke.I fabricated new lower frame rails to tie everything together and then used a thick aluminum skid plate on the bottom as a stressed member also.

Please take this from a fellow BW'er that would rather not see you get hurt and continue to develop your obviously creative fabrication skills.
I'll be glad to help you in any way I can. If welding is an issue, you can send me anything and I'll weld and send back.

We've had biblical-style rain and windstorms that have wreaked havoc across southcentral Alaska. Owen's 200 project may have gotten washed or blown off his deck. Haven't been riding in weeks.

Saturday was different. Cliffosaurus and I scheduled some perfect weather for a ride up the B-29 Trail.

Here's Cliff fording a rain swollen stream:

(Note the brake lever being used on the clutch perch and the absence of a brake lever. A small concession to the original design: the levers can be swapped and the ride continued in the event of a tipover)

I haven't heard of too many engine transplants in the 200s. The Warrior engine would make your bike into a slightly higher performance BW350 with an extra gear.

I'd like to know if the Warrior transmission could be swapped into a BW350 bottom end, as that extra gear would come in handy sometimes.

The angle between the cylinder and case halves is different between the Warrior and BW engines and that might complicate the installation. However, the mounts seem to be very accommodating for a number of builders.

As far as I know, DC Plastics and occaissionally ebay, are the only sources of plastics. At least you have you side panels and that puts you miles ahead in the game.

Here's another shot of Cliffas Pastrana charging hard above the tree line in the Talkeetnas:

Silly question?
Are there any pros/cons to the BW350 vs BW200?
I keep thinking a BW200 would be easier to throw around but I never been on either. Besides price and availability, is there anything else?